Ledge forming system for producing a conjunct nozzle

ABSTRACT

A novel ledge forming system used to attach a polymer retention hub to a thin wall nozzle core to provide an efficient way to produce a conjunct nozzle. The inventive apparatus provides a means for assembly of components by a method involving use of a press with a heating element to elevate temperature of a thermoplastic polymer to permit formation of a ledge that overhangs the flange of a nozzle core, mechanically locking components together. Execution of the process is rapid, low cost and eliminates damage to the thin wall of the core that would occur if the polymer retention hub were molded around the nozzle core.

CROSS REFERENCE TO RELATED PATENTS AND APPLICATIONS

Creation of a Polymer Retention Hub to Form a Conjunct Nozzle Ser. No.13/694,284

Simplistic Approach to Design of a Reusable Nozzle Hub U.S. Pat. No.7,434,753 B2

Method of Making a Thin Wall Nozzle U.S. Pat. No. 7,231,716 B2

Deep Drawn Nozzle for Precision Liquid Dispensing U.S. Pat. No.8,210,455 B2

This application is also entitled to the benefit of Provisional PatentApplication Ser. No. 61/629,187 filed Nov. 14, 2011

FEDERALLY FUNDED RESEARCH

Not Applicable

SEQUENCE LISTING OR PROGRAM

Not Applicable

BACKGROUND OF INVENTION Field of the Invention

This invention pertains to the field of liquid dispensing equipment.More particularly, it pertains to design and method of connection of amolded polymer nozzle hub to a deep drawn nozzle core to construct aconjunct nozzle. The conjoined nozzle forms a unitized assembly througha method of connection that accomplishes this task without the use ofadhesives or expensive insert mold tooling that can damage the thinwalls of the nozzle core. The nozzle hub is the retention device thatholds the core to a luer taper or other outlet and prevents separationunder pressure.

Description of the Prior Art

At present, there are five general types of nozzles used for attachmentto pumps to extricate a viscous liquid to a work piece: (1) a modifiedhypodermic or cannula needle made of a polymer hub with stainless steelmedical tubing inserted and glued to prevent separation or a metal hubor polymer hub with a band swaged to the medical tube, (2) a custommachined metal needle, (3) a molded plastic cone shaped needle, (4) aceramic cone shaped needle, (5) a deep drawn nozzle core assembled topolymer hub to form a conjunct or unitized nozzle assembly.

The modified hypodermic or cannula needle is a standard hypodermicneedle adapted to fit to a standard luer connection on the outlet of apump. A medical gage tube is manufactured, cut to size and de-burred. Itis inserted into a plastic hub using force and heat. The connectionbetween the two parts is glued with an adhesive to provide a fluid tightseal. Variations of this design style use metal or polymer hubs andswage the hub to the medical tube. Metal hubs are swaged directly;polymer versions use a metal band to provide the compressive force. Allof these types are prone to variation in run-out, have restrictive fluidpaths and large pressure drops across the exit aperture.

The custom machined metal needle is made of a single piece of materialand is shaped to emulate a cannula or is conical in shape. This processis expensive, slow and limits design options. Design of needles usingthis process are limited to tools that can be made small enough to fitinside the cavity to remove material by cutting. Surface finish is ofparamount importance and tool marks and machining ridges only serve toincrease the boundary layer and impede flow through restriction asfilled fluids agglomerate behind the exit aperture. Machining alsolimits wall thickness to sections able to withstand the shear force thatresults from taking a cut. Use of exterior chamfers at the tip thin thewall but dilutes the effect of gravity and increases the propensity forwicking of fluid up the exterior wall.

Molded needles are made of polymer materials and are limited to moldingprocess restrictions. Needles of this type have thick walls and have adifficult time holding tight run out tolerances. The parts are low costbut not suitable for placement of small precision quantities of fluid.Thick walls inhibit access into tight areas and impede fluid break offand make wicking of fluid up the exterior of the needle more pronounced.Some design variations have thinner walls produced from more elasticpolymers. They suffer from deflection of the walls as a result of thepressure required at high flow rates, at shut off wall relaxation causesunwanted fluid bolus.

Ceramic needles are generally manufactured using the ceramic injectionmolding process. Using sophisticated mixing technology the powders arecompounded with thermoplastic binders to produce feedstock pellets. Thebinders form a liquid medium that carries the ceramic powders into themold during the injection stage. Molded parts then go through twothermal processes. First is pyrolysis or another method of de-binding toremove the binder, followed by sintering in a high temperature kiln toform the ceramic component. During sintering the component shrinksuniformly by as much as 20% but retains the complex shape. Parts aremolded over size to account for this shrinkage. This process is costly,more suitable to low volumes and produces a needle that may be porousand prone to brittle fracture.

The approach to building a conjunct or unitized nozzle assembly utilizesseveral different processes each best suited for their intended purpose.A deep drawn nozzle core of monolithic construction is used to provide acontiguous fluid path. The fluid path has a thin wall and a smoothinterior surface. It is free of imperfections that cause roughness. Thethin wall enables the exit aperture to be a much larger diameter for agiven gage size than the aforementioned needles used as the prior artitems of commerce in industry today. A retention device capable ofretaining the nozzle core under pressure is important to successfulimplementation and promulgation of the unitized or conjunct nozzledesign style. Successful connection of the nozzle core to the hub is akey aspect. It is accomplished by molding the hub with the requiredmaterial present that can be re-flowed and formed into a ledgeoverhanging the flange on top of the tapered core to provide amechanical lock to prevent separation of the parts. Connection isenabled without the use of adhesives or ancillary devices. The unitizedor conjunct style combines the advantageous features of low cost, thinwall, complete thread, color coding for size indication, contiguous pathmonolithic structure, minimal run-out, smooth interior surfaces andprecise apertures to produce a precision part suitable for use onautomated devices that require precision deposition of fluids.

Objects and Advantages

Accordingly, the design and the method of making unitized nozzleassemblies have inherent objects and advantages that were not describedearlier in my patent. Several additional objects and advantages of thepresent invention are:

-   -   (1.) To provide a method of connecting a deep drawn nozzle core        to a molded polymer retention device by re-flowing polymer        material using heat and pressure to achieve a mechanical lock.    -   (2.) To provide a design for polymer retention device that        contains the geometry necessary to minimize movement of material        to enable re-flow to occur rapidly.    -   (3.) To provide a design for a polymer retention device that        enables a volumetric match of the material re-flowed to the        molded geometry apriori of re-flow.    -   (4.) To provide a design for a polymer retention device that        enables assembly of core to hub without the use of adhesives to        permanently bond the components together.    -   (5.) To provide a method of tooling the connection process of a        deep drawn nozzle core to a molded polymer retention device that        can prevent re-flow of the polymer into the interior standard        taper where connection to a fluid source is facilitated.    -   (6.) To provide a method of tooling the connection process of a        deep drawn nozzle core to a molded polymer retention device that        can prevent heating of the thermally conductive metal core to        enable the polymer retention device to maintain elasticity, not        yield or elongate in order to retain compression against the        core to prevent rotational movement of the core in the assembled        state.    -   (7.) To provide a design for a polymer retention device that        enables the deep drawn metal core to be inserted into the molded        polymer retention device and stop at a constant depth to ensure        re-flowed polymer volume cross section is consistent part to        part to achieve constant strength and rigidity.    -   (8.) To provide a design for a polymer retention device that has        a flat surface opposite of the opening the metal core is        inserted into to support and resist the compressive load        required to form the mechanical lock.    -   (9.) To provide a design for a polymer retention device that has        geometry that can be located and centered easily in the tool        used for support during processing.    -   (10.) To provide a design for a polymer retention device that        maintains a concentric relationship of the polymer retention        device to the deep drawn nozzle core to ensure it is rotatable        in service.    -   (11.) To provide a method of tooling the connection process of a        deep drawn nozzle core to a molded polymer retention device that        uses a tool with elementary geometry that can be easily        maintained and fabricated without the use of complex machine        tools.    -   (12.) To provide a design for a polymer retention device that        has an undercut inherent in the polymer hub that allows for        automated movement of the polymer hub to the fixture where        automated assembly to the deep drawn core occurs.    -   (13.) To provide a design for a polymer retention device that        contains a square extrusion of sufficient size to gain leverage        for use tightening and loosening the retention device.    -   (14.) To provide a design for a polymer retention device that        can be molded in colors chosen to denote deep drawn core        aperture size without requiring use of a mark on the deep drawn        core for indication.    -   (15.) To provide a design for a polymer retention device that        can provide space for a concave company designator for component        recognition.

SUMMARY OF THE INVENTION

The invention is a novel method of design and manufacture for a polymerretention device specifically built to connect to a deep drawn nozzlecore. Nozzle cores require an interface to prevent separation from thestandard taper under pressure generated by transmission of fluid. Apolymer nozzle assembly comprises:

A thin walled deep drawn nozzle core that has a cylindrically shapedtapered wall parallel to the angle formed by a standard taper insertedinto a conically shaped hole that is congruent to the thin tapered wallof the nozzle core where it mates to the standard luer taper designedfor connection to a source of pressurized fluid. A shaped circular fossais conjoined to the top of the conically shaped cavity that extendsthrough the polymer hub. A cusp of circular shape extends upward fromthe surface the shaped circular fossa originates. Width of the crosssection and height of the cusp of circular shape is a function of thevolume required to form an invaginated or enclosed cavity with athickness substantial enough to support a load equivalent to the forcerequired to separate the core from the standard taper. Volume of theformed or solidified profile that supports the required force forseparation is equal to the volume of the circular shaped cusp.Separation force great enough to pull the seated nozzle core from thestandard luer taper is generated by means of a contiguous thread aroundthe circumference of the polymer hub. Below the contiguous thread is asquare shaped cross sectional profile that provides a means to applyadditional torque to the polymer retention device and forms a funduscircumscribed by the minimum diameter of the thread. The fundus profileis preferred to be flat and parallel to the top of the circularly shapedcusp that extends upward from where the fossa originates. However, thefundus shape can have a profile that is radial or conical. A coreinserted into the tapered cylinder shaped hollow fits with interferenceand is pressed into the polymer hub until the exterior flare wall iscoincident to the bottom of the circular shaped fossa. Interior edge ofthe fossa that is adjacent to the tapered cylinder shaped hollow isrelieved by installation of an interior edge chamfer that prevents theexterior flare wall radius from interfering with the coincidentrelationship of exterior flare wall with the bottom of the circularshaped fossa. Pressing the core into the hollow until exterior flarewall bottoms, forces the walls of the polymer hub to expand outwardcreating a pressure acting inward that grips the cylindrically shapedtapered wall of the core inhibiting rotation in service.

Application of a compressive load combined with heat is required tosoften the polymer enough so it can be guided to form an invaginated orinwardly turned enclosed cavity to encapsulate the flange of the nozzlecore. This is accomplished through use of a press combined withresistive heating elements as known in the prior art. A shaped metallicrod with a profile designed to manipulate the heated polymer into thesolidified profile is required. The topside of the core flange isadjacent to the ledge formed by the inwardly turned enclosed cavityafter solidification and functions to capture the flange of the nozzlecore. Ejection of the nozzle core in service is facilitated by formationof the ledge at the top of the invaginated cavity providing a tensile orthrust force through rotation acting on a radial inclined plane thatforms the thread.

To manufacture the connection between the polymer hub and the nozzlecore, support of the fundus is required, this is accomplished by placingthe polymer hub or core retention device into a cylindrical cavity orcounter-bore that circumscribes the square cross sectional profile orform a concave geometry with sides that are adjacent to the crosssectional profile shape that forms the lower portion of the polymerretention hub in a support block with a hole. Geometric shapes such astriangles, hexagons, pentagons, circles or the like can also be used toform the cross sectional profile that forms the lower portion of thepolymer retention device as long as the shapes are properly sized tomaintain a fit that is concentric with the counter-bore contained in thesupport block or form a shaped cavity or nest with sides that areadjacent to the cross sectional profile shape formed by the hub withgenerous relief at corners to ease insertion and removal. A core isinserted into the tapered hollow in the polymer hub. A hole in thecenter of the counter-bore, shaped cavity or nest extends through thesupport block to provide the clearance required for the protrudingportion of the taper terminus to reside. This prevents unintendedimpacts and unintended damage that could result during formation of theenclosed turned in cavity around the core flange.

The ledge-form tool is a heated hollow cylinder of highly thermallyconductive metal that contains a spring-loaded button made ofnon-thermally conductive material. It articulates inward to supply adownward force against the interior radius of the nozzle core flange toprovide a shut off that prevents excess melted polymer from ingress intothe tapered cylindrical wall. Shut-off button action not only preventssealing failure from contaminates that could migrate during manufacturebetween the tapers when components are connected eventually in servicebut it also provides an interior wall to direct the softened polymer toform the interior shape of the edge to the solidified profile. Sacrificeof the salient circular cusp during this procedure is made to providethe softened polymer material required for re-flow to produce a ledgethat overhangs the nozzle core flange. The top of the core flange isadjacent to the underside of the overhung ledge that serves to lock thetop of the nozzle core flange into the polymer retention device.Solidification produces a ledge with a top surface that is parallel tothe fundus. However, other sectional profiles like radii adjacent to thecore flange perimeter, faceted flats or some combination can be used forsupport of load that is not necessarily parallel to the fundus.

These and other objects of the invention will become clearer when onereads the following specification taken together with the drawings thatare attached hereto. The scope of protection sought by the inventor maybe gleaned from a fair reading of the Claims that conclude thisspecification.

DESCRIPTION OF THE DRAWINGS—FIGURES

Turning now to the drawings wherein elements are identified by numbersand like elements are identified by like numbers throughout the sevenfigures, a drawing of the nozzle core with a partial cut away at the topand close up cut away “A” of the bottom of the nozzle is depicted inFIG. 1.

FIG. 2 is an illustrative view of the polymer retention device from avantage point looking downward at an angle and a view looking directlyat the fundus of the retention device;

FIG. 3 is an illustrative view of a nozzle core being manipulated into acut away view of the polymer retention device seated in a support block;

FIG. 4 is a sectional cut away view of the nozzle core as a load isdirected and it is pressed into the polymer retention device seated inthe support block;

FIG. 5 is a partial sectional cut away view of the polymer retentiondevice seated in a support block at the end of the assembly cycle withshut off button depressed and ledge profile formed over the nozzle coreflange;

FIG. 6 is a front view of the assembly system components necessary toperform the process of connection of polymer retention hub to nozzlecore;

FIG. 7 is a cut away section view of a conjunct nozzle showingillustrative details of connection;

FIG. 8 is an illustrative view of the finished polymer retention devicepermanently fastened to the nozzle core to form a unitized or conjunctnozzle looking downward from an elevated vantage point downward;

FIG. 9 shows a view of front side of a forming tool apparatus, a supportblock, a unitized nozzle assembly and a press with a heating elementthat provides a means to withdrawal a ledge-form tool assembly afterforming a conjunct nozzle;

FIG. 10 is a view of two support blocks looking from an overhead vantagepoint looking directly downward, a square nest with a generous relief atcorners and a round nest with a hole in the center are shown.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings wherein the showings are for the purposeof illustrating preferred embodiments of the invention only and not forthe purpose of limiting it. The invention is a novel manner of creatingand a technique of assembling a conjunct nozzle 24 of which the outcomeis depicted in FIG. 8. FIG. 1 shows the thin wall nozzle core 1 in avertical, attitude, as it would be inserted and captured in a retentiondevice 8 and used in service in the industry. The deep drawing processis used to produce the core 1 that is depicted in the illustration. Athin walled deep drawn nozzle core 1 has a tapered exterior cylindricalwall 2 parallel to the angle formed by a standard luer taper as is knownin the prior art. Exterior cylindrically shaped barrel wall 2 orexterior shaped barrel wall 2 extends downward to an exterior conicallyshaped wall 32 that is attached to a taper terminus 5. Terminus 5 isextruded downward to the extent the structure necessary to form an exitaperture 30 is provided. Cores 1 are designed with an exterior flarewall 3 that forms the basis for a flange 4. The interior nozzle coreflange radius 6 provides a nozzle core 1 interior surface that enables ashut-off button 20 to locate, seat and activate to supply downward forcenecessary for prevention of re-flowed polymer from entering and blockingthe interior cylindrically shaped barrel wall 7. This ensures aninterior thin tapered wall 7 that mates with a standard luer taper as isknown in the prior art is free of contaminates that would cause unwantedextrication of fluid through the standard luer taper from transmissionpressure due to an interruption of mating sealing surfaces. Contact ofthe shut-off button 20 against the interior upper flared opening radius6 also allows formation of the shaped edge 23 of the cantileveredsolidified profile formed by re-flow of the salient cusp 9.

FIG. 2 is a view of the polymer retention device 8 in a verticalorientation as produced by the plastic injection molding process as isknown in the prior art before insertion of a thin wall nozzle core 1. Ashaped circular fossa 10 is conjoined to the top of the conically shapedcavity 11 that extends down to a cylindrical relief 33 that cuts throughthe remainder of the polymer hub 8 breaking out through the fundus 14center. Interior edge relief 26 of the fossa 10 that is adjacent to thetapered cylinder shaped hollow 11 is relieved by installation of ainterior edge chamfer 26 that prevents exterior flare wall radius 3 frominterfering with the coincident relationship of exterior flare wall 3with circular shaped fossa bottom 27. A circular shaped cusp 9 extendsupward from the surface the shaped circular fossa 10 originates. Widthof the cross section and height of the circular shaped cusp 9 is afunction of the volume required to form an invaginated cavity 18 with athickness substantial enough to support a load equivalent to the forcerequired to separate the core 1 from the standard luer taper thatconnects it to the source of fluid. Volume of the formed or solidifiedprofile that supports the required force for separation is equal to thevolume as molded of the circular shaped cusp 9. Separation force greatenough to pull the seated nozzle core 1 from the standard luer taper isgenerated by means of a radial inclined plane 12 around thecircumference of the polymer hub 8.

Below the contiguous thread 12 is a square shape cross section 13 thatcould be designed as a round, triangular, pentagonal, hexagonal,octagonal or other shaped cross sectional geometry. A square shapedcross section 13 is selected to provide a means to apply additionaltorque to the polymer retention device 8 to maximize flat length for thesmall size of the retention device 8 that surrounds the nozzle core 1 tofacilitate application of torque away from the weaker corner radii 31 tothe center of the flat of the square cross section 13 where strength isgreater for a polymer hub 8.

A fundus 14 is formed with corner radii 31 that are the result of thefundus 14 circumscribed by the minimum root diameter 34 of the thread12. The fundus 14 has a profile that is flat and parallel to the top ofthe circularly shaped cusp 9 that extends upward from where the fossa 10originates. However, the fundus 14 can assume radial or conical profilesthat are other than flat or parallel to the salient cusp 9.

The sequence of steps required assembling and forming the connectionbetween the polymer retention device 8 and the nozzle core 1 is a keyaspect to the novel method of manufacturing a unitized nozzle assembly24. To accurately show the order of operations required, FIGS. 3, 4, 5are displayed as cut away views of each step that is required to makethe connection with the process.

FIG. 3 is a partial cut away illustration of the first step in themanufacture of the conjunct nozzle 24. To make a connection between thepolymer hub 8 and the nozzle core 1, support of the flat fundus 14 isrequired, this is accomplished by placing the polymer hub 8 or coreretention device 8 into a cylindrical cavity 16 or counter-bore 16 thatcircumscribes the square cross section 13 that forms the lower portionof the polymer retention hub 8 in a support block 15 with a through hole17. A core 1 is inserted in the direction indicated by the arrow intothe tapered hollow 11 in the polymer hub 8.

FIG. 4 shows application of a load to the core 1 that is sufficient toseat the exterior flare wall 3 into the shaped circular fossa 10. Loadis applied until the exterior flare wall 3 is seated against thecircular shaped fossa bottom 27 such that interior edge chamfer 26 doesnot impede the coincident relationship. This forces the tapered hollow11 of the polymer hub 8 to expand outward creating pressure actinginward. The pressure exerted is a function of the elastic behavior ofthe polymer. Appropriate tolerances enable expansion within the elasticlimit of the material to provide a force that grips the cylindricallyshaped tapered wall 2 of the core 1 and helps to inhibit rotation inservice when the unitized polymer hub nozzle assembly 24 is installedand removed from standard luer tapers. A hole 17 in the center of thecounter-bore 16 that extends through the support block 15 providesclearance required for the protruding portion of the taper terminus 5 toreside. This protects cores 1 by preventing unintended impact and damagethat can result during formation of the enclosed cavity 18 around thecore flange 4.

FIG. 5 depicts the last step in the process of formation of theconnection of the polymer retention device 8 to the thin walled deepdrawn nozzle core 1. Support of the polymer hub 8 is achieved byinsertion into the cylindrical cavity 16 contained in the support block15. The through hole 17 prevents unintended impact and damage to theterminus 5 of the thin wall nozzle core 1 that results during formationof the invaginated cavity 18 around the core flange 4. Counter bore 16with a hole 17 in a support block 15 is aligned in a concentric mannerto the ledge form tool 19 thereby enabling the retention device 8 tolocate suitably within the counter-bore 16 and allow the thin walledcore 1 to maintain concentricity. This ensures the ledge-form tool 19will operate correctly and the button 20 will make contact in therequired location on the tapered interior cylindrical wall 7 of the thinwalled deep drawn nozzle core 1. Force and thermal energy is applied tothe forming tool 19 through the cylindrical housing 25 by a thermalpress or some other such device as is known in the prior art.

The ledge-form tool assembly 19 is heated and made from highly thermallyconductive metal that forms a heated hollow cylinder 25 and contains aspring-loaded button 20 made of non-thermally conductive material.Cylindrical housing 25 contains a deep counter-bore 35 that provides acavity to contain a force compliant member 21 and a shallow circulardepression 36 on the opposite side. A small diameter hole 37 providesthe necessary geometry for fit of a button 20. Button 20 articulation isinward against a force compliant member 21 that pushes against athreaded cap 28 and supplies a downward load against the interior radiusof the nozzle core flange 6 to provide a shut off that prevents excessmelted polymer from ingress into the tapered interior cylindrical wall7. Shut-off button 20 action not only prevents sealing failure fromcontaminate occupation between mating taper surfaces when components areconnected eventually in service but it also provides an interior wall todirect the softened polymer to form the interior shape of the edge orshaped edge 23 to the solidified profile. The button 20 also providesforce to aid separation upon completion of formation of the overhang 22.Sacrifice of the salient circular cusp 9 during this procedure is madeto provide the softened polymer material volume required for re-flow toproduce a ledge 22 that forms an overhang 22 to produce the enclosedcavity 18 to trap the nozzle core flange 4. The top of the core flange 4is adjacent to the underside of the overhung ledge 22 that serves tolock the top of the nozzle core flange 4 into the polymer retentiondevice 8. Solidification produces a ledge 22 with a top surface that isparallel to the fundus 14.

FIG. 6 is a front view illustration of tools, component parts of thedesign, force and energy required to initiate forming the unitizednozzle 24. Each of the elements used in the process are arranged in aserial fashion to denote the sequential nature of the operation. Theload required to generate pressure substantial enough to re-flow thepolymer softened by exposure to the elevated temperature of the ledgeform tool 19 is shown schematically using a vertically oriented arrowlabeled load and two horizontal arrows labeled heat. Energy is appliedto the top of the thermally conductive hollow cylindrical housing 25 theform tool 19 is constructed from. The threaded cap 28 contains the forcecompliant member 21 to provide a solid structure for the force compliantmember 21 used to energize the button 20 to push against interior radiusof nozzle core flange 6. A clamp 29 aids separation of a newly formedconjunct nozzle 24 from the spring-loaded button 20 of the ledge-formtool 19. Implementing a restraint 29 ensures a newly formed conjunctnozzle assembly 24 is not lifted from the block 15 in an uncontrolledfashion and damaged inadvertently at the end of the operation. Restraintcan be accomplished by translation of a clamp 29 mounted at the top ofthe support block 15 for lock up of radial inclined plane 12 preventingpull out of conjunct nozzle 24 from nest 16 or by exertion of forceagainst a face of the square shaped cross section 13 or a corner radius31 of polymer hub 8 shaped as a round, triangular, square, pentagonal,hexagonal, octagonal or other shaped geometry to form an alternate crosssection for a nozzle 24 against a datum surface or side wall in acounter bore 16 that is round 40, triangular, square 41, pentagonal,hexagonal, octagonal or other shaped geometry. A square shaped 41counter bore 16 with sides that are adjacent to the square shaped crosssection 13 formed by the polymer hub 8 has generous relief 41 at cornersto ease insertion and removal. Retraction of the shaped metallic rod 19leaves a conjunct nozzle 24 trapped by a restraint 29 in the block 15,withdrawal of the clamp 29 and removal of a finished conjunct nozzleassembly 24 completes the operation.

FIG. 7 is a full section view of a complete conjunct nozzle 24. Core 1is captured in the polymer retention hub 8 by the overhung ledge 22 thatforms an invaginated cavity 18. A shaped edge 23 is produced uponretraction of the shut off button 20 from the upper flared opening 6 asshaped metallic rod 19 withdrawals after completion of the formingoperation.

FIG. 8 is a pictorial representation of a finished unitized nozzleassembly 24 from a slightly elevated vantage point looking downward. Aunitized polymer nozzle 24 has a polymer hub 8 permanently attached tothe nozzle core 1. The nozzle 24 is pointing downward as it would mostlikely be used in service in the industry. Conjunct nozzle 24 sizes aredenoted by a discrete polymer retention hub 8 color for each thin wallednozzle core 1 corresponding with a unique exit aperture size 30.Manufacture of the nozzle assembly 24 using this method is easilyautomated and is accomplished without the use of adhesive that slows theprocess and elevates risk of contamination though migration of excessadhesive by misapplication.

FIG. 9 is an illustration from a level vantage point looking directlyahead showing a front view of a thermal press 39 with a ledge-form toolassembly 19 installed. Press 39 with a resistive heating element 38retracts, withdrawaling a ledge-form tool 19 after forming. Aspring-loaded button advances 20 and a conjunct nozzle 24 remains in thesupport block 15.

FIG. 10 is an overhead view looking downward at two support blocks 15each support block 15 shows a nest 16 or counter-bore 16 with a hole 17in the center, a square nest 41 with generous relief 42 at the cornersand a round nest 40 are shown.

While the invention has been described with reference to a particularembodiment thereof, those skilled in the art will be able to makevarious modifications to the described embodiment of the Inventionwithout departing from the true spirit and scope thereof. It is intendedthat all combinations of elements and steps, which performsubstantially, the same function in substantially the same way toachieve substantially the same result, be within the scope of thisinvention.

What is claimed is:
 1. A forming tool apparatus for a press having aheating element, comprising: a) a cylindrical housing with a deepcounter-bore on one end having a shallow circular depression oppositeend of said deep counter-bore and a small diameter hole through a wallin-between each end that separates said deep counter-bore end from saidshallow circular depression end; b) a button with a large diameter sideand a small diameter side slideably fit inside said deep counter-boreend and into said small diameter hole; c) a force compliant member fitinside said deep counter-bore end presses against said button on saidlarge diameter side; d) a threaded cap fit into said deep counter-boreend pushes against said force compliant member; and e) a support blockbelow that contains a nest having a through hole located in center ofsaid nest, said nest further includes, a concave shaped cavity havingsides that are adjacent to a cross sectional profile shape establishedby a square shape cross section and wherein shaped geometry other thansaid square shape cross section used to establish said lower portionentails configuration of said concave adjacent sides of said nest tosaid cross sectional profile shape of said shaped geometry other thansaid square shape cross section.
 2. The forming tool apparatus for thepress having the heating element of claim 1, wherein said cylindricalhousing is made of metal.
 3. The forming tool apparatus for the presshaving the heating element of claim 1, wherein said button is made ofnon-thermally conductive material.
 4. The forming tool apparatus for thepress having the heating element of claim 1, wherein components of saidcylindrical housing and said support block having said nest arecoaxially aligned.
 5. The forming tool apparatus for the press havingthe heating element of claim 1, wherein said small diameter side of saidbutton limits size of softened polymer surrounding said button todiameter of said small diameter side.
 6. The forming tool apparatus forthe press having the heating element of claim 1, further including arestraint by having translation of a clamp mounted on top of saidsupport block wherein pull out from said nest is prevented.
 7. Theforming tool apparatus for the press having the heating element of claim1, further including said nest in said support block configured to havesides that form a square counter bore with a flat bottom surface or acircular counter bore with said flat bottom surface wherein said throughhole in center of said nest is concentrically aligned with said button.8. The forming tool apparatus for the press having the heating elementof claim 1, wherein said heating element contiguous with saidcylindrical housing on said press elevates temperature of saidcylindrical housing and said press applies force downward until contactis made pushing said button upward, deflecting said force compliantmember permitting said cylindrical housing with said shallow circulardepression to contact a surface and thereby soften and form polymercontained within said shallow circular depression.
 9. The forming toolapparatus for the press having the heating element of claim 1, whereinhaving heated a polymer from contact with said shallow circulardepression end of said cylindrical housing; contiguously attached tosaid heating element, urging of said press directs softened polymermaterial around said small diameter of said button.
 10. The forming toolapparatus for the press having the heating element of claim 1, whereinretraction of said cylindrical housing extends said button therebyassisting separation of said shallow circular depression from contactwith softened polymer after completion of forming operation.
 11. Theforming tool apparatus for the press having the heating element of claim1, further including a conjunct nozzle, wherein withdrawal distance ofsaid cylindrical housing after use exposes said nest thereby permittingremoval of said conjunct nozzle.
 12. A ledge form tool apparatus forapress having a heating element, comprising: a) a thermally conductivehollow cylindrical housing contiguously attachable to said heatingelement to provide a heated hollow cylinder on said press, said heatedhollow cylinder has a shallow circular depression on one end; b) ashut-off button having a large diameter and a small diameter that has aclose clearance slidable fit in a small diameter hole located throughsaid shallow circular depression; c) a deep counter-bore end having aforce compliant member sandwiched between a threaded cap and said largediameter of said shut-off button; and d) a support block having a nestsuitably sized, positioned in said press, said nest further includes, aconcave shaped cavity having sides that are adjacent to a crosssectional profile shape established by a square shape cross section andwherein shaped geometry other than said square shape cross section usedto establish said lower portion entails configuration of said concaveadjacent sides of said nest to said cross sectional profile shape ofsaid shaped geometry other than said square shape cross section.
 13. Theledge form tool apparatus for the press having the heating element ofclaim 12, wherein said support block with said nest mounted under saidheated hollow cylinder is concentric to said shallow circular depressionto surround an exterior thereby transfer heat rapidly to soften and forma polymer.
 14. The ledge form tool apparatus for the press having theheating element of claim 12, wherein said force compliant member pushesagainst said shut-off button having said shut-off button extend andapply a load to insert by said press.
 15. The ledge form tool apparatusfor the press having the heating element of claim 12, wherein said forcecompliant member yields having said shut-off button retract and saidshallow circular depression apply load and transfer heat for forming bysaid press.
 16. The ledge form tool apparatus for the press having theheating element of claim 12, wherein withdrawal of said heated hollowcylinder following forming is arranged, permitting said force compliantmember inside to recover from yield and extend said shut-off button incontact with a surface, pushing said surface away from said shallowcircular depression thereby aiding separation from a softened polymer.17. The ledge form tool apparatus for the press having the heatingelement of claim 12, wherein said shut-off button is made of a materialthat is non-thermally conductive to prevent conductive heat transferfrom contact with said shut-off button.
 18. The ledge form toolapparatus for the press having the heating element of claim 12, whereinsaid small diameter hole is centered in said shallow circulardepression.
 19. The ledge form tool apparatus for the press having theheating element of claim 12, wherein said small diameter of saidshut-off button is limited to a diameter sized to obstruct a standardluer taper from entry of a polymer softened through heat.
 20. A ledgeform tool apparatus comprising: a) a block with a counter bore with anest that further includes, a concave shaped cavity having sides thatare adjacent to a cross sectional profile shape established by a squareshape cross section and wherein shaped geometry other than said squareshape cross section used to establish said lower portion entailsconfiguration of said concave adjacent sides of said nest to said crosssectional profile shape of said shaped geometry other than said squareshape cross section; b) a thermally conductive hollow cylindricalhousing made of metal centered over said counter bore that contains aforce compliant member situated between a threaded cap and a button madeof non-thermally conductive material; c) a shallow circular depressionsurrounding a small diameter hole for fit of said button on end of saidthermally conductive cylindrical housing opposite; said threaded cap;and d) a source of controlled heat.